Method of and means for constructing and erecting building structures formed of bricks, or the like

ABSTRACT

A method of and means for constructing and erecting building structures formed of block-like elements, such as bricks in which the elements are formed into assemblies or sections made up of a plurality of courses cemented together with the end elements of alternate ones of the courses along one side of the assembly extending beyond the ends of the elements of the others of the courses, and the end elements of the other courses along the opposite side of the assembly extending beyond the ends of the end elements of said alternate courses along said opposite side. The method includes the positioning of the assemblies so formed in upright positions for movement toward each other to extend the end elements of the alternate courses of one assembly between the end elements of the other courses of another assembly to permit the joining of the assemblies to complete a building structure. The method also includes the positioning of additional assemblies above a lower portion of a building structure made in accordance with the method of the invention, and supporting such additional assemblies on such lower portion and joining the additional assemblies to form upper portion of the building structure. The invention includes apparatus for holding the assemblies one on top of another in vertically spaced relation for the introduction of mortar therebetween whereby an upper portion of a building structure may be erected on a lower portion thereof.

United States Patent Nichols 51 May2,1972

[54] METHOD OF AND MEANS FOR CONSTRUCTING AND ERECTING BUILDINGSTRUCTURES FORMED OF BRICKS, OR THE LIKE Roy A. Nichols, Route 5, Box1070, Benton, Ark. 72015 22 Filed: M8l.24, 1970 [21] Appl. No.: 22,330

[72] Inventor:

Related US. Application Data [63] Continuation-in-part of Ser. No.846,831, June 19,

1967, Pat. No. 3,503,174.

Primary Examinerl'lenry C. Sutherland Attorney-Charles E. Lightfoot [57]ABSTRACT A method of and means for constructing and erecting buildingstructures formed of block-like elements, such as bricks in which theelements are fonned into assemblies or sections made up of a pluralityof courses cemented together with the end elements of alternate ones ofthe courses along one side of the assembly extending beyond the ends ofthe elements of the others of the courses, and the end elements of theother courses along the opposite side of the assembly extending beyondthe ends of the end elements of said alternate courses along saidopposite side. The method includes the positioning of the assemblies soformed in upright positions for movement toward each other to extend theend elements of the alternate courses of one assembly between the endelements of the other courses of another assembly to permit the joiningof the assemblies to complete a building structure. The method alsoincludes the positioning of additional assemblies above a lower portionof a building structure made in accordance with the method of theinvention, and supporting such additional assemblies on such lowerportion and joining the additional assemblies to form upper portion ofthe building structure. The invention includes apparatus for holding theassemblies one on top of another in vertically spaced relation for theintroduction of mortar therebetween whereby an upper portion of abuilding structure may be erected on a lower portion thereof.

5 Claims, 12 Drawing Figures PATENTEDMIAY 2 I972 3. 6 59 3-91 I SHEET 1CF FIG. I

Roy A. Nichols INVENTOR MMKW ATTORNEY PATENTEDMAY 2 I972 SHEET 2 0F 5Roy A. Nichols INVE N TOR BY g TTORNE Y 7 PATENTEDMAY 2 I912 SHEET 3 BF5 FIG. 7

Roy A Niche/5 'INVENTOR BY f ' ATTORNEY PATENTEDMAY 2 I972 SHEET It 0F 5FIG.8

FIG. I0

Roy A. Nichols ATTORNEY PATENTEDHAY 21972 SHEET 50F 5 Q mZk ATTORNEYMETHOD OF AND MEANS FOR CONSTRUCTING AND ERECTING BUILDING STRUCTURESFORMED OF BRICKS, OR THE LIKE This application is a continuation-impartof a prior application, Ser. No. 646,831, filed June 19, 1967 and nowU.S. Pat. No. 3,503,174 by the same applicant.

BACKGROUND OF THE INVENTION In the laying of bricks, concrete blocks,ceramic tile, and the like, in the construction of buildings, it iscustomary to assemble such elements by placing the same individually incourses in which the elements are more or less uniformly spaced apartwith mortar between the elements to cement the same together. Theelements are usually arranged with the elements of one course offsethorizontally relative to those of the next course, whereby the coursesare tied together by the overlapping arrangement of the elements to forma strong and durable structure capable of supporting the building andresisting cracking or separating of the elements.

The laying of bricks, or the like, in this manner is a tedious and timeconsumming operation calling for the exercise of a high degree of skilland experience in properly positioning the elements and applying themortar in the right amount at the right location.

The present invention has for an important object the provision of amethod of and means for erecting building structures formed ofblock-like elements, whereby such elements may be prefabricated intoassemblies of uniform size and shape and conveniently positioned andsupported in erected condition to be joined together to complete thebuilding structure.

SUMMARY OF THE INVENTION Briefly described, the method of the inventioncomprises the assembling of bricks, or other block-like elements intoassemblies of uniform size andshape by the use of apparatus for holdingthe elements in uniformly spaced apart relation, sealing the spacesbetween the elements throughout one face of the assembly, and applyingmortar between the elements from the other face of the assembly tocement the elements into a unitary structure to be used in erecting abuilding. The elements of each assembly are positioned in courses withthe end elements of alternate ones of the courses extending beyond theend ones of the other courses of elements along one side of theassembly, while the end ones of the elements of said other coursesextend beyond the ends of the end ones of said alternate courses alongthe opposite side of the assembly.

By this arrangement the assemblies may be positioned together with theelements along their adjacent sides arranged in interdigitating relationto permit joining of the assemblies by introducing mortar between theinterdigitating elements to complete a building structure.

The assemblies may be conveniently formed at the brick yard, or othersuitable location, transported in finished form to the building site,arranged in upright positions and moved together to position theextended ends of the courses of adjacent assemblies in interdigitatingrelation, and cemented together to complete the building structure.

The method of the invention also includes the erection of a lowerportion of the building structure in the manner described above, and thepositioning thereon of additional assemblies to form an upper portion ofthe structure, the additional assemblies being supported on the lowerportion of the structure by means which holds the upper assemblies inspaced relation above the lower assemblies for the introduction ofmortar between the uppermost course of the lower assemblies and thelowermost course of the upper assemblies.

BRIEF DESCRIPTION OF THE VIENS OF THE DRAWINGS FIG. 1 is a fragmentaryfront elevational view illustrating the device of the invention andshowing the same in use in the erection of a wall;

FIG. 2 is a fragmentary, side elevational view, partly in cross-sectionand on an enlarged scale, of a portion of the lower end of the device,showing details of structure of means for positioning and holding thelower end of the device in the erection of a wall section therewith;

FIG. 3 is a fragmentary side elevational view partly in crosssection andon a somewhat enlarged scale, of an upper end portion of the deviceshowing details of structure of spacer and holding means for positioningand holding the upper end of the device in the erection of a wallsection;

FIG. 4 is a cross-sectional view, on an enlarged scale, taken along theline 44 of FIG. 1, looking in the direction in dicated by the arrows;

FIG. 5 is a cross-sectional view, on an enlarged scale, taken along theline 5-5 of FIG. 1, looking in the direction indicated by the arrows;

FIG. 6 is a perspective assembly view, on a greatly enlarged scale,showing details of construction of parts of the element clamping andholding mechanism of the invention;

FIG. 7 is a perspective assembly view on a greatly enlarged scale,showing structural details and parts of the seal forming means forclosing the spaces between the elements at the ends of the elementsagainst the outflow of mortar in the cementing of a wall section;

FIG. 8 is a fragmentary side elevational view, on a somewhat enlargedscale of an upper end portion of the device, showing details ofstructure and arrangement of the seal forming means for closing thespaces between the elements at the front of a wall section againstoutflow of mortar during the cementing of a wall section, the sealforming means being shown in position between the elements prior tosealing the same;

FIG. 9 is a view similar to that of FIG. 8, showing the seal formingmeans in its sealing position;

FIG. 10 is a fragmentary, perspective assembly view, on a greatlyenlarged scale of a portion of the seal forming mechanism showing themeans by which the sealing elements are detachably connected to themechanism;

FIG. 11 is a fragmentary perspective view, on an enlarged scale, showingportions of the means by which the seal forming elements of themechanism are secured in place; and

FIG. 12 is a side elevational view illustrating the apparatus and methodof the invention by which a building structure may be assembled.

Referring now to the drawings in greater detail the apparatus of theinvention, as presently illustrated herein, comprises a generallyrectangular frame, generally designated 10, which may conveniently beformed of longitudinally extending, spaced apart, parallel members 12,of angular shape in cross-section, such as the channel members shown,suitably connected together.

Within each of the channels 12 a longitudinally movable rod 16 isslidably mounted in guides, such as that shown at 17 in FIG. 5. Each ofthe rods is connected at its upper end to a link chain 18, or similarflexible connecting element, as best seen in FIG. 5, which is connectedto a rotatable shaft or tube 20, rotatably mounted on upwardly extendingtop end lugs 22 on each end of a header 23 on the end of the frame. Bythis arrangement it will be apparent that when the tubular shaft 20 isrotated in a direction to wind up the chains 18 the rods 16 will all bemoved longitudinally in one direction, and upon rotation of the shaft 20in the other direction the rods 16 will be allowed to movelongitudinally in the other direction. The shaft 20 may have one or morestop lugs, such as that shown at 24 in FIG. 5, with which a latch ordetent member 26, hingedly mounted on the frame, is positioned forengagement at its free end, to releasably hold the shaft 20 againstreverse rotation when the shaft has been turned in the winding-updirection of the chains 18. The shaft 20 may be rotated by any suitablemeans such as by providing diametrically opposite openings thereinthrough which a lever or rod 21 may be inserted, as shown in FIG. 5.

At the left side of the frame 10, as shown in FIG. 1, a short auxiliaryshaft 20' is rotatably mounted on a pair of lugs 22' similar to the lugs22, the shaft 20 being aligned with the shaft 20 and being connected tothe rod 16', which is similar to the rods 16, for actuation in a similarmanner by rotation of the shaft 20'.

Within each of the channels 12, a number of springplates or washers 28are positioned on each rod 16 and 16 at uniformly spaced intervalsthereon, each of which plates is movable with the rod in one directionby a cross-pin 30, or the like carried by the rod, as clearly shown inFIG. 5. Coil springs 32 surround the rods 16 each of which springs bearsat one end against one of the spring caps or plates 28 and at the otherend against a spring cap or plate 34 through which the rod 16 is freelyslidable.

At suitably spaced intervals along the lengths of the channel members12, stationary, plate-like, clamp elements 38 are secured to the bottomsof the channels, extending exteriorily therefrom, and spaced in the samedirection and at the same distance from each of the elements 38, thechannel is provided with generally U-shaped bottom slots or openings 40,through each of which a rockingly movable clamp element 42 is extended,as best shown in FIGS. and 6. Each movable clamp element 42 has aplate-like portion 44 which is disposed exteriorily of the bottom of thechannel 12 across the bottom thereof in parallel alignment with clampelement 38, and an inward extension 46 which projects inwardly of thechannel and is provided with an elongated opening 48 through which oneof the rods 16 is slidably extended. Each clamp element 42 also hasspaced apart lugs 50 whose free ends are curved and which are extendedthrough the arms of the U-slot 40 for engagement with one of the springcaps 34.

The above described clamping mechanism is for the purpose of holdingbricks, or other block-like structural elements on the frame in properlyspaced relation for the introduction of mortar into spaces therebetweento form a unitary wall section or other building unit. The frame is usedby placing it in a generally horizontal position with the clamp elements42 in released positions and the springs 32 extended. This may beaccomplished by rotating the shaft to allow the spring caps 28 to moveaway from the caps 34, to allow the clamp elements 42 to rock away fromthe clamp elements 38. With the clamp mechanism thus released, bricks B,are then inserted between the clamp elements to rest on the externalfaces of the bottoms of the channels 12 as seen in FIG. 5, whereupon theclamps are actuated by rotation .of the shaft 20 to compress springs 32and rock the elements 42 to clamp the elements into engagement with thebricks.

For the purpose of closing the spaces between the bricks at locations toprevent the outflow of the mortar when introduced therebetween, sideseal forming elements 60, shown in detail in FIGS. 8, 9 and 10, areprovided to close the spaces along the longitudinal sides of the bricks,and end seal forming elements 62, shown in detail in FIG. 7, areprovided to close the spaces at the ends of the bricks.

The side seals 60 may take the form of lengths of rubber tubingextending across the width of the frame 10, and within each seal thereis a flat rod 64 which is wider than the diameter of the tubing. Therods 64 are suitably mounted on curved arms 66 having generally T-shapedlugs 68 on their outer ends which are shaped to be extended throughkey-hole like slots 70 in the rods 64 in the manner illustrated in FIG.10, to releasably connect the rods to the arms. By this construction,the rods 64 may be detached from the arms 66 to allow the seal formingelements 60 to be removed and replaced when necessary.

The arms 66 are pivotally connected, loosely at their other ends tocranks 72, rotatably attached to the flanges of the channels 12, as bymeans of loops 74 on the arms.

The cranks 72 are actuated by longitudinally extending rods 76 in thechannels, which are connected at one end to slotted lugs 78 carried on ashaft 80, rotatably mounted on one end of the frame. By this mechanismthe seal forming elements are positioned to be located in the spacesbetween the bricks B when the bricks are positioned on the frame, asseen in FIG. 8,

and upon actuation of the cranks 72 in one direction, the flat rods 64will be rotated to actuate the seal forming elements 60 into sealingcontact with the bricks as seen in FIG. 9 to close the spaces across theframe against the outflow of mortar therefrom. When the mortar has set,the cranks 72 are rotated in the other direction to rotate the rods 64to release the seal forming elements 60, as shown in FIG. 5. The sealforming elements are secured to the exterior faces of the bottoms of thechannels 12 so that the flat rods 64 may be turned in the elements whilethe elements remain stationary.

The end'seal forming elements may be of rod-like shape, formed ofsuitable seal forming material, such as rubber, these elements 62 alongone side of the frame being preferably of a length to extend across theend of one brick and across the spaces on each side thereof into sealingengagement with the adjacent bricks to close the spaces between the endsof bricks on one frame and adjacent bricks which have already beenassembled in a wall or other building structure.

Similar end seal forming elements 62' are provided on the frame, whoselength is the same as the width of one brick, to close the end spacesbetween the bricks.

The seal forming elements 62 extend longitudinally of the frame 10 andare mounted on angle brackets 82, each having a perforated arm 84 formedwith downturned side marginal portions.86 positioned to'fit along theside edges of lugs 88 on elongated support members 90, shown in FIG. 7,extending longitudinally along and secured to the flanges of thechannels 12 in the spaces between the channels. The support members 90also have lugs 92 whose free ends are extended partly across the spacesbetween the channels 12 and to which the seal forming elements or tubes60 are cemented, whereby the tubes are held stationary againstrotational movement at locations between the channels when the rods 64are rotated in the tubes.

Support members 90 similar to the members 90 are also positioned onflanges of the channels 12, which are formed with lugs 92 positioned inalignment with the lugs 92, but without the lugs 88, as best seen inFIG. 11.

The frames of the invention will usually be used by placing the same ina substantially horizontal position with the clamp elements 42 inreleasing position. The bricks are then placed in position thereon withspaces between the bricks as indicated as S within which the sealforming elements 60 and 62 extend. When the frame has been thus filledwith bricks the clamp rods 16 are actuated by rotation of shaft 20 tosecurely clamp the bricks in place and the seal forming elements 60 areactuated by rods 76 by rotating shaft 80 to close the spaces against theoutflow of mortar.

In order to construct an upright wall, or other building structure,making use of a number of building units constructed with the frames asdescribed above, means is provided for positioning the frame vertically,one on top of another with the bricks still clamped thereon, whereby thebuilding units may be assembled in vertical alignment to form the wall.

For this purpose auxiliary supporting frames 10 provided at their upperends with a tubular cross member or track 100, best seen in FIG. 1,attached to the end of the frame by longitudinally projecting lugs 102,while the frames 10 are provided with spaced apart rollers 104 at theirlower ends by which an upper frame may be supported on a lower one formovement along the track to locate the upper frame in proper positionwith the laterally extending ends of alternate ones of the bricksextending between bricks of a previously assembled portion of the wallpreparatory to filling in the spaces with mortar. The rollers 104 may beof a circumferentially grooved type shaped to fit the curvature of thetrack 100 and lare preferably rotatably mounted in roller housings 106or the ike.

The roller housings 106 are preferably positioned between adjacent onesof the channels 12 and secured thereto for bodily tilting movement, asby means of a pivot pin 120. Each of the housings 106 has an opening 122which is positioned to be in registration with an opening 124 in theflange of one of the channels and through which openings a pin may beextended to hold the housing in its upright or untilted position. Byremoving the pins the housings 106 may be tilted, as shown in FIG. 4, tofacilitate the removal of the frame from the track 100 without danger ofdislodging the bricks when the frame is to be taken off of a section ofbricks which have been laid and cemented.

The frames are similar to frames 10, having the same clamp elements 38and 42 which are operated by the same mechanism, but the frames 10' arenot provided with the side and end sealing elements for closing thespaces between the bricks.

In order to support the lowermost frame in an upright position where thewall is to be erected relative to a previously positioned footing orslab F, as shown in FIG. 2, a trackway 100' may be provided, which maybe of semi-circular shape in cross-section, mounted on spaced apart bars108, or some similar device, each of the bars having an end notch 110for engagement with an edge of the footing F to position the trackway100 parallel thereto and each bar 108 having a pivotally adjustableextension or brace 112 pivotally attached to its free end, as by meansof a thumb screw 114, as seen in FIG. 2, whereby the extension 112 maybe adjusted to hold the track 100 substantially parallel to the footing.By this arrangement the lowermost frame may be positioned in apredetermined position relative to the footing or other structure towhich it is to be related. Suitable seal forming means, such as a rubbertube 60 may be positioned on the footing F adjacent to the track 100,beneath the lowermost course of the bricks B, to close the space betweenthe lowermost bricks and the footing against the outflow of mortarintroduced therein.

The track 100 may be connected, as by means of a tie-wire 103, to thefooting F, to hold the lower end of the frame against movement away fromthe footing.

Spacer means may also be provided for holding the upper ends of theframes in predetermined spaced relation to a wall or other uprightstructure, such as an inner wall W of a house, as shown in FIG. 3,wherein the frame may have an elongated member 116 of channel shape incross-section connected at one end thereto adjacent each top corner ofthe frame and into whose outer end an elongated member 118 istelescopingly extended. The member 116 may have a longitudinal slotthrough which a screw 120 is extended for threadable engagement with themember 118 to hold the members at any desired position of extension.

By this means the members 116 and 118 may be extended and positioned forengagement of the outer end of the members 118 with the wall W to holdthe upper end of the frame in a predetermined spaced position relativeto the wall. A tiewire may also be connected to the wall W, and to thescrew 120 to hold the frame against tilting movement away from the wall.

In making use of the invention the frames 10 are positioned horizontaland the bricks placed thereon and clamped in place. The loaded framesare then positioned on the track 100 in side-by-side upright positionsand moved together to extend the projecting end portions of alternatebrick of one section laterally of the frames between the alternate endportions of brick of the adjacent section. With the frames thusassembled the rods 76 may be actuated to sealingly engage the seals 60with the bricks to close the spaces S.

It is to be noted that in assembling the bricks on a frame 10 alternateones of the end bricks along the right side of the frame will beextending beyond the left side of the frame and will be clamped by theclamps of only one of the channels 12, as seen in FIG. 1, while the endones of the bricks on the left side of the frame in the same rows as theprojecting brick on the right side of the frame are located laterallyinwardly from the left side of the frame to provide spaces into whichthe projecting bricks on the right side of the adjacent frame may beextended when the frames are positioned together. Thus,

when two loaded frames 10 are placed upright and moved togetherprojecting bricks on one frame will fit into spaces between the bricksof the adjacent frame, the projecting ends being then positioned to beclamped in the adjacent frame by operation of the short shaft 20'whereby bricks of both frames will be held in property spaced assembledrelation.

With the frames thus assembled, mortar may be introduced by any suitablemeans, such as hoses or flexible tubes, into the spaces between thebricks to cement the same together.

When the mortar has set in a portion of a wall thus formed, the frames10 may be removed by releasing sealing forming elements 60 and clampelement 42 and moving the frames away from the bricks. Support frames 10may then be clamped to the first laid wall sections in the locationsfrom which the frames 10 were removed, and additional loaded frames 10positioned on the support frames and assembled in the same manner toform an upper portion of the wall. In the same manner additional loadedframes 10 may be supported on support frames 10 clamped to lowerportions of the wall to assemble and cement further wall sections above.

As shown in FIG. 12, the apparatus of the invention, by which upperassemblies of the block-like elements may be positioned above a lowerportion of a building structure, may include auxiliary frames 10 eachconstructed in the same manner as the frames 10 previously described,which are clamped in position on the assemblies forming the lowerportion L of the building, and upon whose tubular tracks 100, the frames10, carrying the upper assemblies may be supported to allow the upperassemblies to be moved together and joined to each other and to thelower portion L to form an upper portion of the structure. The framesfor clamping and holding the completed assemblies in position to formthe building structure, need not, of course, have the seal forming means60 and 62 and their operating mechanism, but are provided with theclamping elements 38 and 44 and the operating mechanism therefor,whereby the supporting frames 10" may be securely clamped to the lowerportion of the structure to hold the tracks in position to support theframes of the upper assemblies thereon.

It will thus be seen that the invention constructed and used asdescribed above, provides a means for assembling bricks, or the like insections, cemented together and which may be used for the erection ofbuilding structures without the necessity of manually placing the mortarand laying courses of bricks individually, thus greatly reducing thetime and labor consumed in the erection of brick structures.

Having thus clearly shown and described the invention, what is claimedas new and desired to secure by Letters Patent IS 1. A method ofconstructing an in-situ building structure of block-like structuralelements, comprising:

loading a first plurality of said block-like structural elements in afirst holding apparatus,

fastening said structural elements in said first holding apparatus inuniformly spaced courses with the end elements in alternate coursesprojecting beyond one side of the apparatus and the other end elementsin the same alternate courses being spaced inwardly of the other side ofsaid apparatus.

positioning said holding apparatus in an upright vertical position on apredetermined level,

loading a second plurality of said block-like structural elements in asecond holding apparatus,

fastening said second plurality of structural elements in said secondholding apparatus similarly to the first plurality in said first holdingapparatus.

positioning said second holding apparatus in an upright position on thesame predetermined level as the first holding apparatus,

moving said second holding apparatus toward the first holding apparatuswhereby the end elements intermesh, actuating a portion of one of saidholding apparatus to securely hold said intermeshed end elements, and,flowing mortar between said elements,

permitting said mortar to set, and, removing said holding apparatus.

2. A method according to claim 1 wherein said predetermined level is atrack and said second holding apparatus is rolled toward said firstholding apparatus on said track.

3. A method according to claim 1 wherein said predetermined level is atthe footing of said building structure.

1. A method of constructing an in-situ building structure of block-likestructural elements, comprising: loading a first plurality of saidblock-like structural elements in a first holding apparatus, fasteningsaid structural elements in said first holding apparatus in uniformlyspaced courses with the end elements in alternate courses projectingbeyond one side of the apparatus and the other end elements in the samealternate courses being spaced inwardly of the other side of saidapparatus. positioning said holding apparatus in an upright verticalposition on a predetermined level, loading a second plurality of saidblock-like structural elements in a second holding apparatus, fasteningsaid second plurality of structural elements in said second holdingapparatus similarly to the first plurality in said first holdingapparatus. positioning said second holding apparatus in an uprightposition on the same predetermined level as the first holding apparatus,moving said second holding apparatus toward the first holding apparatuswhereby the end elements intermesh, actuating a portion of one of saidholding apparatus to securely hold said intermeshed end elements, and,flowing mortar between said elements, permitting said mortar to set,and, removing said holding apparatus.
 2. A method according to claim 1wherein said predetermined level is a track and said second holdingapparatus is rolled toward said first holding apparatus on said track.3. A method according to claim 1 wherein said predetermined level is atthe footing of said building structure.
 4. A method according to claim 3wherein said holding apparatus are positioned whereby said elements abutan upright structure.
 5. A method according to claim 1 wherein saidpredetermined level is the top of frames clamped to a previouslymortared portion of block-like structural elements.